TSB: 03-003/05

2004-2005 MAZDA3 - DRIVE SHAFT CLICK NOISE

APPLICABLE MODEL(S)/VINS

2004 – 2005 Mazda3 with VINs lower than JM1 BK**** 51 271699 (Produced before January 1, 2005)

DESCRIPTION

Some vehicles may exhibit a click noise from the drive shaft when changing gear direction and/or taking off. The symptom is a single click. This concern is created by a small contact surface between the wheel hub and driveshaft which causes high contact pressure and stick-slip to occur.

Service washers have been established to address customer concern.

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

Before starting, prepare the following items:

• Two (2) special washers (BPYK-33-044)

• Two (2) new lock bolts (9YA0-21-083D). (Note: Bolts are NOT reusable)

  

Tools required

• ” impact wrench

• 13mm, 14mm, 17mm, 21mm impact sockets

• 14mm box wrench

• Hammer

• Punch

• Torque wrench (ft-lb)

• Marker or scribe

• #240 sand paper

• Brake caliper support hooks (or equivalent)

The following procedure must be done on both sides. Select either side and proceed to step 1.

1. Verify concern.

2. Remove wheel.

3. Remove brake caliper by removing two (2) 17mm bolts. Be sure to support caliper with hook (or equivalent) to prevent brake line tension and damage.

4. Remove rotor and set aside.

5. Remove one (1) 13mm center lock bolt and discard.

6. Disconnect ABS speed sensor connector.

7. Remove ABS speed sensor bracket by removing one (1) 14mm bolt.

8. Remove stabilizer link from strut.

9. Remove tie-rod end ball joint locking pin.

10. Remove 14mm tie-rod ball joint nut.

11. Separate ball joint from steering knuckle by tapping lightly with hammer.

12. Remove 14mm pinch bolt and nut.

13. Pull down on lower control arm to separate it from steering knuckle.

14. Tap drive shaft end lightly with hammer and punch to separate it from steering knuckle. Move steering knuckle if needed to completely separate from drive shaft.

15. Remove ABS dust cover by tapping lightly with hammer and chisel. Be careful not to damage drive shaft.

NOTE: Do not reuse the ABS dust cover because the washer will replace it. The washer has two purposes: (1) to eliminate the clicking noise and (2) to take the place of the ABS rotor dust cover.

16. Polish drive shaft surface where it contacts wheel hub. Use #240 sand paper (or equivalent) sourced locally. Surface should be smooth to the touch. Degrease surface as a final cleaning.

17. Install special washer, with protruded surface (black side) facing driveshaft. Make sure drive shaft fits inside washer protrusion.

18. Reinstall drive shaft to steering knuckle. Make sure washer stays in place between drive shaft and wheel hub. Do not install lock bolt yet.

19. Reinstall lower control arm to steering knuckle. Tighten to 31.8 – 43.3 ft-lbf.

20. Reinstall ball joint to tie-rod end. Tighten to 27.3 – 37.1 ft-lbf.

21. Reinstall locking pin.

22. Reinstall wheel speed sensor bracket and stabilizer. Tighten to 29.8 – 40.3 ft-lbf.

23. Reinstall wheel speed sensor connector.

24. Install NEW lock bolt (9YA0 21 083D) and tighten until snug but do not torque.

25. Check special washer fit to ensure concentricity to drive shaft. This can be done by slowly rotating the drive shaft and checking washer movement for one (1) complete turn.

• If washer is properly installed, the movement will be even.

• If not properly installed, the washer will wobble noticeably. If washer does wobble, loosen lock bolt, reposition washer, repeat steps 24 – 25.

26. Once washer is confirmed to be installed correctly, torque lock bolt to 23.3 – 28.3 ft-lbf. Mark or scribe bolt, then tighten it further until marking has moved 85 to 95 degrees.

27. Reinstall brake rotor and caliper. Tighten caliper bolts to 75.3 – 87.0 ft-lbf.

28. Reinstall wheel. Tighten lug nuts to 65.1 – 86.7 ft-lbf.

29. Perform steps 2-28 on opposite side.

30. Verify repair.

PART(S) INFORMATION

Local source #240 sand paper (or equivalent).

WARRANTY INFORMATION

NOTE:

• This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair. Refer to the Warranty Wizard for warranty term information.

• Additional diagnostic time cannot be claimed for this repair.